Bruce 
i didn't get a replacement from Catalina direct but I did replace my rudder.  I believe I got mine from foss foam. It was somewhat cheaper but that is not the reason I purchased from them. They seemed to have more of a track record than the mfg that Catalina direct used.  I have been pleased so far with the performance but the shape of the rudder is way different than the one I replaced
regards

Mike, 

I had the marina drop my rudder in the fall because a small crack was developing. I've ground that out and am patching. I'd rather not pay the marina to put it back on. Any tips? Did you need to replace stuffing box material?

John,
the packing material is the same stuff you use in the stuffing box, pretty cheap if i recall.  as far a replacing the rudder, i don't have any suggestions other that having access to a travel lift.  I guess you could dig a really deep hole(just kidding).  cost of the travel lift shouldn't be that great, i think they charged be around 200~300 bucks but they did it in conjunction with re-launching the boat.
I got instructions from Catalina(I think) on how to install the stuffing material but is basically just to cut it to size and then it is pressed in as you tighten the fitting.  
hope that helps.
regards,

I have had my rudder off the boat twice. It was called out in the survey to have a moisture issue. "Digging a hole" could be a good possibility, if your "On the Hard" allows. Travel lift might be your best bet. I removed mine while on the hard. I carefully jacked the stern with several jack stands until I got it high enough to allow it to drop. I also was on a gravel base which allowed me to move some of the gravel without digging a hole.
If you have your current rudder out than you know has to be done, if not here is what I found on my own.

• Collar at top of rudder was seized (aluminum to SS) Needed to cut collar to remove rudder after struggling many hours.
• You will need to dismantle the steering quadrant
• The packing gland will need to be loosened than you should be able to drop the rudder
• On reassembling you might want to make some spacers to minimize any up and down movement. should there be any play.
• If installing a new rudder I believe you are going to need to re-drill the cross hole in the rudder post  for the steering quadrant.

Note should you decide to jack stern. Be careful, do the jacking after all is disassembled and ready to go. Do not leave the boat jacked in this position unless you are ready to reassemble at the same time.
 

I knew I wasn't going to be around for the haul out, so I had the marina do the drop. I actually can dig a hole, a boat two boats away did. I gave the marina a good head start with penetrating oil on the cap and quadrant. It must have gone smoothly because they only charged a half hour. 

I took note of everything I could see. I just missed the drop and what was in the stuffing box. Thanks for the info folks. 

Years ago I had foss replace a rudder on a oday 322 that was totally delaminates.  They actually used the shaft and super structure of the old rudder which was fine.